CN113039141B

CN113039141B - Conveyor idler monitoring apparatus, systems, and methods

Info

Publication number: CN113039141B
Application number: CN201980073971.XA
Authority: CN
Inventors: 奥斯瓦尔多·巴乔; 爱德华多·马蒂内利
Original assignee: Superior Industries Ltd
Current assignee: Superior Industries Ltd
Priority date: 2018-10-30
Filing date: 2019-10-30
Publication date: 2023-02-28
Anticipated expiration: 2039-10-30
Also published as: US20230271787A1; US20220033190A1; US11608230B2; CN113039141A; CA3118131A1; WO2020092657A9; WO2020092657A1; BR112021008191A2

Abstract

Conveyor idler monitoring apparatus, systems, and methods are provided. In some embodiments, one or more sensors (e.g., temperature sensors, load sensors, etc.) are supported by shafts of conveyor idlers. In some embodiments, one or more sensors are in data communication with a wireless transmitter. In some embodiments, a generator driven by rotation of the idler is in electrical communication with one or more sensors and/or wireless transmitters. In some embodiments, a plurality of idler monitoring systems are in data communication with the conveyor monitoring system and/or the operation monitoring system.

Description

Conveyor idler monitoring apparatus, systems, and methods

Technical Field

The invention relates to conveyor idler monitoring.

Background

Current conveyor idler systems include sensors for monitoring the characteristics of the idlers within the system.

Disclosure of Invention

A conveyor idler monitoring method includes one or more sensors supported by shafts of conveyor idlers. One or more sensors are in data communication with the wireless transmitter. An energy generator rotationally driven by the idler gear is in electrical communication with the one or more sensors and the wireless transmitter.

Drawings

Fig. 1 is a perspective view of an embodiment of a conveyor idler.

Fig. 2 is a cut-away side view of the conveyor idler of fig. 1.

FIG. 3 is a side view of an embodiment of an idler shaft.

Fig. 4 is a top view of the idler shaft of fig. 3.

FIG. 5 is a side view of an embodiment of a load cell.

Figure 6 schematically illustrates an embodiment of an idler monitoring system.

Fig. 7 is a cut-away elevation view of another embodiment of a conveyor idler.

FIG. 8 schematically illustrates another embodiment of an idler monitoring system.

Fig. 9 illustrates an idler network monitoring system.

Fig. 10 is an end view of an embodiment of a generator.

Fig. 11 is a side view of an embodiment of a conveyor pulley.

Fig. 12 shows a detail area a of fig. 11.

FIG. 13 illustrates an embodiment of a user interface screen.

FIG. 14 illustrates an embodiment of a user interface screen.

FIG. 15 illustrates an embodiment of a user interface screen.

Detailed Description

Referring to the drawings (like reference numbers designate identical or corresponding parts throughout the several views), fig. 1 and 2 illustrate an embodiment of a conveyor idler 100. The conveyor idler 100 includes a cylinder 130 rollingly supported on an axle 200. The shaft 200 is supported (e.g., in a fixed manner) on the conveyor. The cylinder 130 is configured to at least partially support the conveyor belt B.

Idler 100 optionally includes end disks 140-1, 140-2 disposed at opposite ends of shaft 200 and mounted to opposite ends 220-1, 220-2 of cylinder 130. Each end disk is optionally supported on an associated bearing 160 (e.g., a ball bearing). A seal assembly 150 is optionally provided outboard of each bearing assembly to at least partially prevent external liquids and/or debris from entering the interior volume of idler 100.

Referring to fig. 2, a monitoring system 600 (e.g., one of the monitoring system embodiments described herein) is optionally at least partially supported on the shaft 200.

Referring to fig. 3 and 4, one or

more mounting plates

260, 262 are optionally mounted to the shaft 200 to support one or more electronic components of the monitoring system 600. In some embodiments, the load sensor 500 is supported on (e.g., mounted to) the shaft 200. In some embodiments, a cavity 250 is provided in the end 220 of the shaft 200 to accommodate a transmitter and/or other components of the monitoring system. An opening 230 is optionally provided in the shaft to at least partially accommodate one or more electrical connectors (e.g., wires, cables, etc.) that optionally connect the transmitter to the load cell 500 and/or other components supported on the shaft 200 (e.g., on the mounting plate 260). In some embodiments, the transmitter is at least partially housed in the cavity 250. In alternative embodiments, the cavity 250 may be omitted and the transmitter optionally mounted on the end 220 of the shaft or elsewhere on the idler and/or conveyor.

In some embodiments, one or more cavities 240 are provided adjacent to (e.g., radially inward of) the bearing 160. In some embodiments, each cavity 240 is provided in the radially outer surface of the shaft 200. In some embodiments, a temperature sensor 635 (e.g., a resistance temperature detector, thermocouple, etc.) is at least partially housed in one or more cavities 240.

Referring to fig. 5, an embodiment of a load sensor 500 is shown. The load cell 500 optionally includes a deflector arm 510. One or more strain gauges 550 are optionally mounted to the deflector arm (e.g., in a Wheatstone bridge or other arrangement). The deflector arm 510 is optionally mounted to the shaft 200 (e.g., an upper surface of the shaft, disposed between the shaft and the conveyor belt, etc.), such as by one or more bolts 512. The deflector arm 510 is optionally spaced apart (e.g., vertically spaced apart) from the shaft 200 by a spacer 520. A bolt 514 or other device optionally applies a load between the deflector arm 510 and the shaft 200. A rounded lower surface 530 (e.g., a ball) optionally at least partially transfers load between the deflector arm 510 and the shaft 200. Bolt 514 is optionally adjustable to increase or decrease the load on lower surface 530. Rounded lower surface 530 is optionally positioned at or near an axial midpoint of shaft 200 (e.g., at or near a location equidistant from ends 220-1, 220-2). Deflection of the shaft 200 optionally changes the deflection of the deflector arm 510 such that the one or more strain gauges 550 produce a modified strain signal related to the amount of deflection of the shaft 200.

Referring to fig. 6, an embodiment of a monitoring system 600 is schematically illustrated. The load sensor 500 (e.g., a load cell and/or strain gauge thereof) is optionally in data communication with the processor 625 (e.g., optionally via an amplifier 640 that is optionally configured to convert an analog signal to a digital signal). One or more temperature sensors 635 are optionally in data communication with the processor 625. A vibration sensor 620 (e.g., optionally mounted to the shaft 200) is optionally in data communication with the processor 625. The real time clock 630 is optionally in data communication with the processor 625. The processor 625 optionally transmits signals (e.g., at least partially processed signals) from the various sensors to the processor 610, which is in data communication with the processor 625. The processor 610 optionally is in data communication with a memory 615 (e.g., an SD card or other memory)). The processor 610 is optionally in fluid communication with a transmitter 605 (e.g., an antenna). Transmitter 605 optionally includes a wireless transmitter (e.g., a WiFi interface access point). Transmitter 605 is optionally disposed at least partially in cavity 250. Transmitter 605 is optionally in data communication (e.g., wireless communication) with monitor 690. Monitor 690 optionally includes a graphical user interface. In some embodiments, monitor 690 comprises a mobile computing device, such as a consumer computing device (e.g., a smartphone, tablet, laptop, etc.).

Referring to fig. 7 and 8, another embodiment of a conveyor idler 800 and an associated (e.g., integrated) idler monitoring system 700 is shown. Idler 800 is optionally substantially similar to one or more of the other idler embodiments described herein; in some embodiments, the idler 800 includes an optionally modified shaft 200' that rollingly supports the cylinder 130. Optionally modified cavity 250 '(e.g., in or near shaft 200') optionally at least partially houses transmitter 605. The idler pulley 800 optionally contains an identifier 810 (e.g., an RFID tag or QR code) that may be provided at or near the end of the shaft 200'. A sensor housing 820 (e.g., a generally annular housing) is optionally mounted to the shaft 200', such as optionally inside the cylinder 130 and optionally between the bearings 160.

As shown in fig. 8, the idler monitoring system 700 optionally includes one or more components (e.g., transmitter 605, clock 630, processor 610, processor 625, memory 615, load sensor amplifier 640, bearing temperature sensor 635) described as part of the previously described system 600. Idler monitor system 700 also optionally includes one or more additional devices in data communication with transmitter 605, such as one or more load sensors 720, vibration sensors, energy generator 1000, cylinder temperature sensors 735, ambient temperature sensors 740, and angle sensors 750. In some embodiments, one or more sensors (e.g.,

sensors

735, 740, and/or 750) are mounted to the circuit board 702, which may also support one or more components described as part of the previously described system 600 (e.g., clock 630, processor 610, processor 625, memory 615, load cell amplifier 640, etc.). The circuit board 702 is optionally supported on (and/or optionally at least partially housed in) a housing 820.

The one or more load sensors 720 optionally include strain gauges mounted directly to the shaft 200'. In some embodiments, load cell 720 is mounted to a curved (e.g., cylindrical) surface of the shaft; in other embodiments, one or more load sensors are mounted to a machined surface in the shaft and/or a surface supported on the shaft. In some embodiments, a first load cell 720a is mounted at a first location on the shaft 200' and a second load cell 720b is mounted at a second location on the opposite side of the shaft. In some embodiments, the

load cells

720a, 720b are mounted at the same or similar distances from the ends of the shaft, such as at or near the lateral center of the shaft.

The one or more vibration sensors 725 are configured to detect vibrations of the idler (e.g., the bearings 160) and generate corresponding signals and/or corresponding data to the processor and/or transmitter. In some embodiments, vibration sensor 725 comprises a noise sensor (e.g., an electret microphone). In some embodiments, one or more vibration sensors 725 are in contact with the bearings 160.

One or more cylinder temperature sensors 735 are optionally configured and positioned to detect the temperature of the inner surface of the cylinder 130. In some embodiments, the sensor 735 includes an infrared temperature sensor, optionally facing the inner surface of the cylinder 130. In some embodiments, the sensor 735 is at least partially housed in the housing 820, and optionally an opening 821 is provided in the housing 820 between the sensor 735 and the inner surface of the cylinder 130.

One or more ambient air temperature sensors 740 (resistance temperature detectors, etc.) are optionally configured and positioned to detect the temperature of the ambient air inside the idler.

One or more angle sensors 750 (e.g., accelerometers, etc.) are optionally configured and positioned to generate signals related to the orientation of the idler (e.g., idler shaft) relative to the horizontal. It should be appreciated that in the embodiment of a slotted idler assembly, idler wheels mounted on the left, right, and center of the assembly may have different orientations that may be used to identify the mounting location of the idler wheels on the assembly.

One or more energy generators 1000 are optionally configured and positioned to generate electricity through rotation of cylinder 130 about axis 200'. Turning to fig. 10, an embodiment of an energy generator 1000 is shown. The energy generator 1000 optionally includes an inner ring 1040 configured to be supported on (and optionally to remain stationary with) the shaft 200'. Energy generator 1000 optionally includes an outer ring 1020 configured to be supported in (e.g., press fit into) cylinder 130 and optionally rotate therewith. In some embodiments,

protrusions

1022, 1042 or roughness elements or other elements are provided on the inner surface of the inner ring 1040 and/or the outer surface of the outer ring 1020, respectively. A plurality of radially arranged magnets 1030 (e.g., permanent magnets such as neodymium magnets) are optionally supported in the outer ring 1020. A plurality of radially arranged electromagnetic coils 1050 (e.g., electrically conductive coils such as copper coils). In operation, the outer ring 1020 rotates with the cylinder 130 to generate energy that is optionally transmitted to an energy storage device (e.g., a battery, a capacitor) and/or power consuming components of the system 700). In some embodiments, energy generating pulses are also emitted and/or processed by system 700 to determine the number of revolutions and/or rotational speed of cylinder 130. In some embodiments, one or more clamps 1010 are positioned to secure the outer ring 1040 to the cylinder 130.

One or more rotation sensors are optionally provided to detect the rotational speed and/or number of revolutions of cylinder 130. In some embodiments, the speed and/or number of revolutions of cylinder 130 is determined using signals generated by energy generator 1000, and thus energy generator 1000 may be considered a rotation sensor. In other embodiments, a different or additional rotation sensor (e.g., a Hall effect sensor, etc.) is provided.

In some embodiments, the rotational speed of the cylinder 130 is compared to a belt speed (e.g., a measured or assumed belt speed) to estimate a current cylinder diameter and/or a current cylinder wear percentage. For example, in some embodiments, an adjustment factor based on a comparison between cylinder rotational speed and belt speed may be applied to a nominal cylinder diameter in order to determine a current cylinder diameter. The wear percentage of the cylinder 130 may be determined by dividing the current cylinder diameter by the nominal cylinder diameter. The calculation steps described herein may be performed by a processor connected to or remote from the idler.

Referring to fig. 9, an idler network monitoring system 900 (which may also be referred to as a conveyor monitoring system) is schematically illustrated. In some embodiments, multiple systems 700 (e.g., transmitters 605 thereof) are in data communication with a communication gateway 950 (e.g., a LoRaWAN gateway, the specification of which is provided by the LoRa alliance, of fremont, california). In other embodiments, the gateway 950 may be replaced by or supplemented with another communication device, such as a WiFi access point. The gateway 950 is optionally in data communication (e.g., via an internet connection) with an application server 960 (e.g., a cloud-based application server). Application server 960 optionally provides data and/or analysis (e.g., fault analysis, diagnostics, etc.) to web interface 980, mobile device 990, and/or database 970 (e.g., cloud-based database 970).

In some embodiments, application server 960 (or other system or device) receives one or more measurements related to idlers (e.g., one or more of the measurements performed by system 700) described herein. Application server 960 optionally includes or utilizes an algorithm (e.g., a machine learning algorithm, an artificial intelligence algorithm, a neural network algorithm, a deep learning algorithm, a JSON interface, etc.) to predict an idler-related diagnosis (e.g., a maintenance interval, a fault event, a time of the fault event, a first failed component, etc.) from the measurement-based idler-related measurements. In some embodiments, the application server identifies an existing idler fault based on one or more idler related measurements (e.g., temperature, idler rotational speed relative to belt speed or nominal idler rotational speed, axle load, etc.).

In some embodiments, the idler wheels are registered (e.g., by scanning or taking an image of the identifier 810) using a registration device 920 (e.g., including a scanner, camera, etc.). In some embodiments, registration device 920 includes a Global Positioning (GPS) system or device and optionally identifies the position of each idler at the time of registration. The registration device is optionally in data communication with the system 900 (e.g., via a gateway, network interface, or other component).

Referring to fig. 11 and 12, in some embodiments, a pulley 1100 is optionally provided with one or more load cells 1200 for measuring the load applied to the pulley. In some embodiments, the pulley 1100 includes a cylinder 1150 (e.g., metal or other material) having a surface 1125 (e.g., rubber or other material) supported thereon. In some embodiments, the surface 1125 supports one or more radially-outward extending sleeve lock elements 1122 (e.g., ceramic, rubber, or other material). In some embodiments, one or more load cells 1200a are disposed on the cylinders 1150 (e.g., below the surface 1125). In some embodiments, one or more load cells 1200b are disposed between surface 1125 and optionally modified sleeve lock element 1122'. In some embodiments, the wheel 1100 includes a wireless transmitter (not shown) in data communication with a load cell associated with the wheel; in some embodiments, the wireless sensor associated with the pulley is in data communication with a gateway or other communication device of a conveyor monitoring system (e.g., system 900).

In some embodiments, the monitoring systems described herein are configured to continuously monitor sensor output and continuously report sensor output or processed sensor output. In some embodiments, the monitoring systems described herein are configured to continuously monitor sensor output, but only report sensor output or processed sensor output at scheduled intervals (e.g., 10 seconds, 30 seconds, 1 minute, 5 minutes, 10 minutes, 30 minutes, 1 hour, 3 hours, 1 day, etc.). In some embodiments, the monitoring systems described herein are configured to continuously monitor sensor output, but report sensor output or processed sensor output only when one or more sensor outputs or processed sensor output exceeds a threshold (e.g., a threshold temperature, a threshold vibration level, etc.). In some embodiments, the monitoring systems described herein are configured to only energize and monitor sensor outputs at planned intervals, and to report sensor outputs or processed sensor outputs at such intervals or at different intervals.

Referring to fig. 13, in some embodiments, a user interface (e.g., mobile device 990 or network interface 980, see fig. 9) is configured to display a summary screen 1300 containing various monitoring data generated by system 700. In some embodiments, map 1301 illustrates the position of one or more idlers associated with system 700, which may be superimposed on the remotely sensed image of the conveyor and/or station. An image 1305 of the idler is optionally displayed. An idler's serial number 1302 is optionally shown. A battery life indicator 1304 may be displayed. The configuration menu 1306 is optionally used to indicate the location of and/or navigation to a given idler on the conveyor (e.g., by selecting a station, conveyor, portion of the conveyor, and/or which idler in an idler assembly is of interest). The alarm confirmation interface 1310 optionally indicates whether an alarm associated with the idler has been confirmed and/or allows a user to confirm the alarm. Real-time monitoring display 1320 optionally displays one or more idler measurements (e.g., load, bearing temperature, rotational speed, cylinder ambient temperature, cylinder internal surface temperature, vibration level, etc.). In some embodiments, selecting one or more idler measurements in display 1320 may cause the interface to display a graph 1400 of historical values for the one or more idler measurements (see fig. 14). In some embodiments, an alarm history 1330 is displayed to indicate which measurements for the idler wheel have triggered the threshold alarm. In some embodiments, an aggregated display 1500 (see fig. 15) may be accessed that includes aggregated

measurement displays

1510, 1520, 1530 for a plurality of idlers.

In some embodiments, the user interface displays a predicted idler related diagnosis (e.g., maintenance interval, fault event, time of fault event, first time component failure, etc.) based on the idler related measurements. In some embodiments, the user interface displays an indication (e.g., an alarm) corresponding to an existing idler fault determined based on one or more idler related measurements (e.g., temperature, idler rotational speed relative to belt speed or nominal idler rotational speed, shaft load, etc.).

Recitation of ranges of values herein are intended to include both the maximum range value and the minimum range value, and all values within the range provided are intended to be included. The headings used herein are for the convenience of the reader only and should not be construed as limiting or for any other purpose.

While various embodiments have been described above, the details and features of the disclosed embodiments are not intended to be limiting, as many variations and modifications will be apparent to those skilled in the art. Accordingly, the scope of the present disclosure is intended to be broadly construed and includes all variations and modifications within the scope and spirit of the appended claims and equivalents thereof.

Claims

1. A method for monitoring a plurality of conveyor idlers, each of the conveyor idlers having a cylinder with an inner surface and an outer surface, the cylinder being rollingly supported on an axle by a plurality of bearings, the method comprising:

using a first temperature sensor associated with each of the conveyor idlers;

measuring a first temperature of one of the bearings of each of the conveyor idlers;

measuring a rotational speed of each of the conveyor idlers;

measuring a vibration level of each of the conveyor idlers using a vibration sensor;

transmitting data including the first temperature, the rotational speed, and the vibration level to a wireless receiver using a transmitter associated with each conveyor idler;

powering at least one of the transmitter, the first temperature sensor, and the vibration sensor with an internal generator, wherein the internal generator is associated with each of the conveyor idlers, the internal generator generating electricity at least in part by rotation of each of the conveyor idlers;

transmitting, by a gateway, the data to an application server, wherein the data comprises the vibration level; and

displaying current values of the first temperature, the rotational speed, and the vibration level on a user interface; and

predicting, on the application server, a predicted time to failure for each conveyor idler based on the first temperature, the vibration level, and the rotational speed using an artificial intelligence algorithm; and displaying a fault indication associated with at least one of the plurality of conveyor idlers on the user interface, the fault indication being based on the predicted time to failure for each of the conveyor idlers.

2. The method of claim 1, further comprising:

measuring a second temperature inside the cylinder using a second temperature sensor disposed inside the cylinder, wherein the data includes the temperature.

3. The method of claim 1, further comprising:

measuring an orientation of each of the conveyor idlers using an angle sensor, wherein the data includes the orientation.

4. The method of claim 1, further comprising:

powering the first temperature sensor with a battery; and

displaying battery life on the user interface.

5. The method of claim 1, further comprising:

an internal generator is used to power the load sensors associated with each of the conveyor idlers.

6. The method of claim 1, further comprising:

measuring a number of rotations of each conveyor idler of the plurality of conveyor idlers, wherein the data includes the number of rotations.

7. The method of claim 1, further comprising:

displaying a historical value of at least one of the first temperature and the vibration level.